Storage system and article retrieving method

ABSTRACT

An apparatus is disclosed that provides a storage system designed to allow pickers to easily and efficiently pull products from all portions of the storage system from a single side of the storage system. The storage system includes a first storage rack that has a first plurality of columns and a first platform extending from one of the first plurality of columns. An outer edge of the first platform forms an end of the first storage rack. Positioned adjacent to the first storage rack is a second storage rack with a second plurality of columns and a second platform that extends from one of the second plurality of columns, where an outer edge of the second platform forms an end of the second storage rack. An aisle is formed by a predetermined distance between the outer edges of the first and second platforms.

BACKGROUND

The present disclosure generally relates to a storage system thatprovides easier access to multiple portions of a storage rack.

Storage systems are used in warehouses, department stores, and storagefacilities to store products thereon. The storage systems containing aplurality of storage racks may hold large amounts and a variety ofproducts that consumers or pickers pull from. Some storage systems aredesigned in a manner to provide support with insufficient accessibility,thereby requiring additional resources and time for workers to pull allof the products they require to fill a particular order. For example,some storage systems include a horizontal bar that extends to anotherstorage system adjacent thereto; the horizontal bar provides support forboth storage system structures. However, the horizontal bar obstructsthe pathway for the consumer or picker to access products on an oppositeside of the horizontal bar.

SUMMARY

A storage system and method that provides greater accessibility to agreater number of products is provided.

The storage system comprises a first storage rack that includes a firstplurality of columns; and a first platform extending from at least oneof the first plurality of columns, wherein a first outer edge of thefirst support bar forms an end of the first storage rack; a secondstorage rack that includes a second plurality of columns; and a secondplatform extending from at least one of the second plurality of columns,wherein a second outer edge of the second platform forms an end of thesecond storage rack; and the first storage rack is positioned adjacentto the second storage rack, and the first and second outer edges of thefirst and second platforms are a predetermined distance from each otherthereby creating an aisle.

Another storage system is also provided herein, wherein the storagesystem includes a first platform having an outer edge and positionedabove a base surface; and a second platform having an outer edge andpositioned above the base surface, the outer edge of the first platformpositioned a predetermined distance from the outer edge of the secondplatform.

As another example, a storage rack is also disclosed herein, wherein thestorage rack includes a base surface; a first column directly orindirectly attached to the base surface; and a support bar directly orindirectly attached to the first column, wherein the support bar extendssubstantially perpendicular from the first column, the support bar isconfigured to support a pallet, wherein a distance between the basesurface and the support bar forms a space configured to extend a reachof a worker.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a storage system in accordance withaspects of the disclosure;

FIG. 2 is a front view of the storage system in accordance with aspectsof the disclosure;

FIG. 3 is a side view of the storage system in accordance with aspectsof the disclosure;

FIG. 4 illustrates a support bar of the storage system in accordancewith the present disclosure;

FIG. 5 illustrates a vertical support bar in accordance with aspects ofthe disclosure;

FIG. 6 depicts the storage system implemented on multiple levels inaccordance with aspects of the disclosure;

FIG. 7 is a front view of the storage system with a second level inaccordance with aspects of the disclosure; and

FIG. 8 depicts the storage system placed against a wall in accordancewith aspects of the disclosure.

Like reference numerals indicate similar parts throughout the figures.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)

The present disclosure may be understood more readily by reference tothe following detailed description of the disclosure taken in connectionwith the accompanying figures, which form a part of this disclosure. Itis to be understood that this disclosure is not limited to the specificdevices, methods, conditions or parameters described and/or shownherein, and that the terminology used herein is for the purpose ofdescribing particular embodiments by way of example only and is notintended to be limiting of the claimed disclosure.

Also, as used in the specification and including the appended claims,the singular forms “a,” “an,” and “the” include the plural, andreference to a particular numerical value includes at least thatparticular value, unless the context clearly dictates otherwise. Rangesmay be expressed herein as from “about” or “approximately” oneparticular value and/or to “about” or “approximately” another particularvalue. When such a range is expressed, another embodiment includes fromthe one particular value and/or to the other particular value.Similarly, when values are expressed as approximations, by use of theantecedent “about,” it will be understood that the particular valueforms another embodiment.

Reference will now be made in detail to the exemplary embodiments of thepresent disclosure, which are illustrated in the accompanying drawings.

A storage system 100 according to the present disclosure includes atleast two adjacent support platforms 102, 202. Support platforms 102,202 are elongated and positioned off the floor. Support platforms 102,202 are spaced apart from each other by a defined distance, creating anaisle therebetween. In a preferred embodiment support platforms 102, 202are designed to accommodate a standard shipping pallet. For multi-levelstorage systems, vertical columns are provided to support an upperlevel. Horizontal beams are connected to the columns for support of theupper level and also define a width of the aisle. Storage system 100provides access to all of the items stored on the platforms.

Storage system 100 described herein includes a first and second column104, 106, and a support bar 120 that is directly or indirectly attachedto either the first or second column 104, 106, or both. Support bar 120creates part of a first storage platform 102 that provides support forthe products that are stored thereon. Horizontal bar 140 extends fromsecond column 106 to support bar 120, but does not go beyond support bar120. In this regard, an area covered by and adjacent to support bar 120,first and second columns 104, 106, and horizontal bar 140 may beconsidered one storage unit. Further, support bar 120 may extend beyonda plurality of columns past the second column 106, thereby creatingadditional storage units for more products to be stored on. A secondstorage platform 202 is positioned adjacent to storage platform 102 andinclude similar components to storage platform 102. An aisle 190 isformed between support bar 120 and support bar 220. In this regard, aworker is able to safely access products in subsequent storage units(e.g., second, third, fourth storage units) that are beyond the firststorage unit.

As illustrated in FIG. 1, aisle 190 is formed between storage platforms102 and 198. The aisle 190 is formed between support bars 120 and 220 ofstorage platforms 102 and 202, respectively. The formation of storageplatforms 102 and 202 and the formation of aisle 190 is discussed inmore detail below.

As illustrated in FIGS. 1-3, first and second columns 104, 106 stand ina vertical position, perpendicular to base level 160 (e.g., the floor).First and second columns 104, 106 provide support for other componentsof storage system 100 so that storage system 100 is able to hold variousproducts. First and second columns 104, 106 may have one or more bores108 thereon in order to fasten other components to storage system 100,such as by using bolts 110. Other fastening methods are contemplated,including, but not limited to, rivets or welds. For instance, beam 184positioned at an upper portion of first column 104 is attached to firstcolumn 104 via bolts 110. Beam 184 is one of a plurality of beams thatprovide support to the overall structure of storage system 102. Asillustrated in FIG. 1, beam 184 extends across between storage platforms102 and 202 as well and provides support to beam 204. It should benoted, however, that although beam 184 is utilized in the presentstructure, storage systems 102 and 202 may be designed without thepresence of beam 184. It should further be noted that first and secondcolumns 104, 106 each may be a single column or a plurality of columnsjoined together.

As another example, as illustrated in FIG. 1 first column 104 isattached to connecting portion 122 of support bar 120 via bolts 110.Other ways to fasten the support bar 120 or other components to firstand second columns 104, 106 are also possible, such as notches in thecolumns that components can slide into and out of. Furthermore, theremay be a plurality of bores, notches, etc. on first column 104 to allowadjustability of the component attached thereto, like support bar 120.

First and second columns 104, 106 may also have base portion 112 at abottom end of the columns that provide sufficient support to the overallcolumns. Base portion 112 may be adapted so that support bar 120 cannotgo below a level of base portion 112. Alternatively, base portion 112may have a cut-out or otherwise be designed so that support bar 120 orother components connected thereto is not obstructed by the presence ofbase portion 112. It should be noted that any discussion of additionalcolumns herein may be designed similar to first and second columns 104,106 described above.

Support bar 120 is attached to first column 104 via one of the attachingmethods discussed above (e.g., bolts). Although FIG. 1 depictsconnecting portion 122 of support bar 120 extending vertically across aplurality of bores of first column 104, the attachment mechanism is notrestricted thereto, but rather connecting portion 122 may extend longeror shorter along first column 104. Alternatively, connecting portion 122may be welded to first column 104 or be integrally formed.

As shown in FIG. 1, support bar 120 extends horizontally outward fromfirst column 104 in an arcuate manner. It should be noted that supportbar 120 does not necessarily have to be a single structure, but may be aplurality of bars coupled together. Each bar of the plurality of barsmay be various shapes and sizes as well, such as shorter or longerlengths, shorter or longer widths, or some bars being stronger or weakerstructurally than others to support various weights.

Support bar 120 extends from first column 104 and curves at a rightangle at arcuate portion 124. In this regard, support bar 120 has afirst portion 126 that arches at arcuate portion 124 and extends towardand across second column 104 at second portion 128 of support bar 120.The second portion 128 of support bar 120 may extend across the entirestorage system 100, depending on how many columns beyond second column106 the storage system 100 incorporates. It should be noted that thestorage system 100 is not limited to any number of columns. As shown inFIG. 1 and discussed further below, the support bar 120 may form an endof storage system 100 in that no other bars extend beyond support bar120.

Arcuate portion 124 of support bar 120 is a single piece of metal thathas been hydraulically bent to create the arching curve. As discussedabove, however, arcuate portion 124 of support bar 120 may be puttogether by a plurality of support bars, such as two support barsslightly curved that attach in the middle of the curve. In addition,support bar 120 or any other component of storage system 100 (e.g.,first and second columns 104, 106, vertical support bar 180, etc.) maybe manufactured from metal, but other materials are also considered. Forexample, if lighter products are being stored on storage system 100 thena strong plastic material may be possible.

Support bar 120 is designed with an arcuate portion 124 to provide anon-cornered surface. Thus, when a picker accidently walks into or skimstheir leg against the arcuate portion, the picker's leg will avoidinjury on the smooth surface. The picker may be the person or workerwhose responsibilities include going to the storage system 100 andpulling products therefrom. For example, the picker may drive a forkliftor other type of truck capable of holding products to the variousstorage systems to fill an order. When the picker gets to the particularstorage system with the product they need, they go over to the storagerack, pull the necessary products, and put the products on the truck.From here, the picker will go to the next storage system to pull thenext required product.

If the support structure created a right angle that formed a corner, apicker's leg may be injured. However, it should be noted that thepresent disclosure is not restricted to a particular curve or shape. Forexample, more obtuse or acute curves may be implemented as well.Alternatively, a right angle may be formed. A protective padding orother material may be placed over the support structure, whether thesupport structure is curved or not, to help avoid injury to workers. Thepadding is not restricted to the right angle or curved section, but overany portion of storage system 100 where there may be potential forinjury.

As illustrated in FIGS. 2-4, the support bar 120 is spaced above theground to provide additional foot room for pickers. The additional spaceabove the ground may be anywhere from 5-15 inches, but is not restrictedthereto. The space may be even as low as 1 inch but as high as threefeet. For example, as shown in FIG. 4 there is a 10 inch space betweenbase level 160 and support bar 120. Support bar 120 being positioned ata slightly raised level above base level 160 creates a space for a userto slide their foot underneath support bar 120. This way, the picker hasa couple of more inches of space to pull products off of storage system102, thereby extending the picker's reach to grab products. Forinstance, when the products on the storage system begin to deplete,remaining products may be positioned near the back of storage platform102, such as near first and second columns 104, 106. The couple of extrainches provided by the user's feet may not only help and make thepicker's job easier, but may also help avoid injury due to awkwardpositioning when lifting. If support bar 120 was directly against theground or did not provide enough space for a picker's foot to gounderneath, then the picker would be constrained to the distanceprovided by the bar when reaching for products.

Second portion 128 of support bar 120 connects with first horizontal bar140. First horizontal bar 140 is connected to second column 106, inwhich first horizontal bar 140 may be connected using bolts, notches,etc. as described above with respect to connecting portion 122 and firstcolumn 104. First horizontal bar 140 is attached to support bar 120 andprovides support in conjunction with support bar 120 to products thatare stored on that portion of storage system 102. In this regard, thespace adjacent to and formed between and around the first column 104,support bar 120, and first horizontal bar 140 may be considered onestorage unit. Each storage unit on storage system 100 may be capable ofholding one pallet of product. It should be noted the present disclosureis not restricted to any particular size pallet or amount of material,but can be customizable based on the particular needs of the business.For instance, the pallet and units may be designed smaller or largerbased on the particular business, requirements, products, etc. Asillustrated in FIG. 1, adjacent storage platform 202 also includesstorage units that are lined up with the storage units of storageplatform 102. It should be noted support bar 120 is depicted as a bar tohold pallets of products, a platform or any other structure capable ofproviding support may be used as well.

Subsequent storage units beyond the first storage unit may also beformed in a similar fashion. For example, as shown in FIG. 1 there is athird column 150 and fourth column 154, respectively, that are adjacentto second column 106. Second horizontal bar 152 is attached to the thirdcolumn 150 and a third horizontal bar 156 is attached to the fourthcolumn 154. Second horizontal bar 152 and third horizontal bar 156attaches to support bar 120. The portion of storage platform 102 formedbetween and adjacent to third and fourth columns 150, 154, second andthird horizontal bars 152, 156, and support bar 120 may be considered asecond storage unit. Any number of additional storage units can be addedbeyond the first and second storage units in a similar fashion. Itshould be noted the distance between second and third horizontal bars152, 156 may depend on the particular business and desired structure,which in turn may affect the size of the second storage unit generated.Further the distances between all horizontal bars and the positioning ofthe support bar may vary as well based on the particular products andneeds of the business.

Referring back to second and third horizontal bars 152, 156, neitherhorizontal bar extends beyond support bar 120. In this regard, supportbar 120 forms an end of storage platform 102 in that no other componentsof storage system 100 extends therebeyond. Similarly, storage platform202 includes a plurality of columns and horizontal bars attached theretothat do not extend beyond support bar 220.

In this regard, all of storage platforms 102 and 202 may be accessiblefrom first side 192 and second side 194 without any obstruction. Priorart types of storage systems may position two separate storage systemsacross from each other and connect them via horizontal bars at heightthat obstructs human movement, so that the horizontal bar providessupport for both storage systems. In this scenario, however, a picker isunable to access units beyond the horizontal bars unless they climbover, move around, or bend underneath the horizontal bar(s). This notonly raises safety concerns, but also makes the job of the picker moredifficult and thereby wastes resources. Alternatively, the picker isforced to move on the other side of the storage system to access theproducts, such as by maneuvering a truck or walking. This also takesadditional time and wastes resources.

By removing the horizontal bar from extending between storage platforms102 and 202, a picker that is pulling product from first side 192 ofstorage platform 102 is able to walk through aisle 190, and pullproducts from subsequent storage units of storage platform 102 on secondside 194, as illustrated in FIG. 1. These subsequent storage units wouldtypically be accessed by driving a truck to the other side of thestorage system, but due to the removal of the obstructing horizontal barthe user is able to access the storage units on the second side 194instantly and simultaneously. It should be noted, however, that althoughthe figures depict no structural bars of storage system 100 extendingbeyond support bar 120, the present disclosure is not restrictedthereto. Rather, structural bars or component may extend beyond supportbar 120, as long as the aisle 190 is maintained for the picker to walkthrough and access the products on subsequent storage units. Forinstance, support structures may extend beyond support bar 190 thatprovide additional support.

As shown in FIG. 5, storage system 100 of the present disclosureimplements a vertical support bar 180 that is positioned beneath firstand second horizontal bars 140, 152. Vertical support bar 180 providesadditional support for first and second horizontal bars 140, 152.Vertical support bar 180 may be positioned a certain distance fromsupport bar 120 so that a foot of a worker does not accidently hit intovertical support bar 180. In this way, positioning vertical support bar180 a distance from support bar 120 helps reduce the chances of injuryto the worker. The distance from support bar 120 to vertical support bar180 may be, for example, anywhere from one to ten inches. It should benoted, however, that the present technology is not limited to verticalsupport bar 180 being one to ten inches from support bar, rathervertical support bar 180 may be positioned at any location beneath firstand second horizontal bars 140, 152. In addition, vertical support bar180 may be positioned at other locations as well, such as beneathsupport bar 120 or at a connection point of second and third horizontalbars 152, 156 and support bar 120. Multiple vertical support bars 180are also possible, such as multiple vertical support bars implementedbeneath second horizontal bar 140, support bar 120, or a combinationthereof. Additionally, although FIG. 1 depicts vertical support bar 180beneath both horizontal bars, it may be positioned under just one. Forinstance, both horizontal bars may have their own vertical support bar180. The location and positioning of the vertical support bars maydepend on the overall structural design of the storage system 100 andthe needs for the particular business, and may range anywhere betweenand including both ends of the particular bar.

Vertical support bar 180 may be secured to base level 160 by bolts. Forinstance, a bottom portion of the vertical support bar 180 may lay flatto base level 160, the flat portion of which is capable of receivingbolts to secure vertical support bar 180 to base level 160. Asillustrated in FIG. 4 vertical support bar 180 is attached to a bracket182. Bracket 182 is in turn attached to first horizontal bar 140 andsecond horizontal bar 152. First and second horizontal bars 140, 152rest on bracket 182, bracket 182 being secured to vertical support bar180. Although in the examples shown in FIG. 4 vertical support bar 180is separate from bracket 182, these components may alternatively beformed of the same piece of material.

As another alternative, first and second horizontal support bars 140,152 may be replaced with a single horizontal bar. In this scenario, thesingle horizontal bar may provide support for products on the first unitand the second unit. Vertical support bar 180 may attach to, or be madeintegral with, the single horizontal bar.

As shown in FIGS. 6 and 7, storage system 100 described above may bepositioned on multiple levels as well. For example, the columns of thestorage system may extend upward to a second level to support anadditional storage system. Alternatively, separate columns may be usedon subsequent levels. Thus, the columns used on the second level areseparate from the columns on the first level. The second level may alsoimplement vertical support bar 180 as described above so that there isnot a horizontal bar extending between two separate storage systems.Thus, the horizontal bar ends at the support bar and the picker is ableto grab products at subsequent units on the second level. In addition,the second level may include a base 260 in the form of an aisle forpickers to walk on. The base may be a metal or wood board that is strongenough to withstand the weight of at least one worker and variousproducts. It should be noted that the storage system may be implementedon any number of levels above the first and second levels.

Storage system 100 may have units positioned on both sides of thecolumns. For example, storage platforms 102 and 202 each have two setsof storage units on both sides of the columns. The storage units on bothsides of the columns may be designed similarly on both sides. In thisregard, both sides of the storage units may be considered symmetric.This way, rows of storage platforms 102 and 202 repeat themselvesthroughout a warehouse. As an alternative, a separate set of columns maybe used for the opposite side storage system, in which the separate setof columns may be positioned adjacent to the columns used for storagesystem 100.

Storage system 100 described above may be placed against a wall or in anopen area. For instance, FIG. 8 illustrates storage systems 100 againsta wall. In this regard, an arm length of a forklift may influence theamount of storage units of the storage system. For example, if theforklift can carry two-pallets deep, then a business may only want astorage system against a wall to be two storage units deep. Furthermore,if the storage platform 102 is in an open area then the storage system100 may be four storage units deep. This way the forklift can placeproducts two-pallets deep from both sides of the storage system, thusutilizing the four storage units of the entire storage system 100.However, as discussed above the size of the storage units and palletsmay be influenced by the particular business. In this regard, if abusiness is capable of using a forklift to carry four (or any number)pallets of product, then the business may use a four storage unitstorage system positioned against the wall. Similarly, if the storagesystem is positioned in the open then the storage system may be eightstorage units deep (i.e., four on both sides).

The foregoing is advantageous in that a picker is able to moreefficiently pull additional products at a single time. Thus, when apicker is positioned on one side of a storage system to pull productsand they need products from the other side of the storage system aswell, the picker can instantly and simultaneously pull those products bywalking through the unobstructed aisle. This saves time so that the userdoes not have to drive their truck or walk around to the opposite sideof the storage system to pull the needed product. In addition, theadditional space created between the support bar and the ground allowsthe user to be slightly closer to the products to pull, thus making thepicker's job easier and helping to avoid injury.

While the above description contains many specifics, these specificsshould not be construed as limitations of the invention, but merely asexemplifications of preferred embodiments thereof. Those skilled in theart will envision many other embodiments within the scope and spirit ofthe invention as defined by the claims appended hereto.

1-16. (canceled)
 17. A storage rack, comprising: a base surface; a firstcolumn directly or indirectly attached to the base surface; and asupport bar directly or indirectly attached to the first column, whereinthe support bar extends substantially perpendicular from the firstcolumn, the support bar is configured to support a pallet, wherein adistance between the base surface and the support bar forms a spaceconfigured to extend a reach of a worker.
 18. The storage system ofclaim 17, wherein the distance between the base surface and the supportbar is 1-15 inches.
 19. The storage rack of claim 17, furthercomprising: a horizontal beam extending from the first column, whereinthe horizontal beam is positioned above the storage rack and providessupport to a second base surface.
 20. The storage rack of claim 17further comprising a platform formed by the support bar.